Vibration_Maintenance__PWS_(28_Apr_16).docx

PERFORMANCE WORK STATEMENT (PWS)

FOR

MULTI-SHAKER VIBRATION SYSTEM SERVICE

WEST DESERT TEST CENTER

DUGWAY PROVING GROUND

DUGWAY, UTAH 84022

PREPARED BY:

JIM BARNETT

Chief, Physical & Environmental Branch MIL-STD-810 Test Section Test Support Division 14 March 2016

Table of Contents Section 1 General Description of Services/Introduction

1.6 Local Requirements……………………………………………………………………… 3

Section 5 Performance Requirements………………………………………………………………………………… 7

Section 1. General Description of Services/Introduction

1.1. Background: West Desert Test Center (WDTC) procured a three (3) inch displacement Multi-Shaker vibration system. The vibration system included amplifiers, cooling units, and slip table, cabling and controller system. The Multi-Shaker vibration system was procured by WDTC through a contract with Spectral Dynamics Inc. (SDI). The system was also installed by SDI in accordance with (IAW) the provisions of the contract. However, WDTC does not have the required personnel or capability to perform the required services and preventive maintenance as outlined in the manufactures maintenance requirements. In order to maintain the vibration system in accordance with the manufactures service and preventive maintenance a maintenance contract is required to perform the equipment services and preventive maintenance of the multi-shaker system and its subsystems. The service and preventative maintenance must be performed by a qualified experienced technician who understands this one of a kind multi-shaker system.

1.2. Objective: The objective of this service contract is to procure the required services for the maintenance and services on the multi-shaker vibration system and subsystems as required IAW Preventative Maintenance Program for Multi-Shaker system.

1.3. Scope: The contractor shall perform the required services IAW the requirements listed in the Preventative Maintenance Program for the Multi-Shaker system, maintenances manuals and warranty requirements and provide all service replacement parts, filters, oils, and seals as required.

1.4. Type of Contract: This contract shall be a service/maintenance contract with a base year and two (2), 12 month option periods. This contract will be a sole source service contract as only Spectral Dynamics Inc. is authorized to service certain components of the system due to proprietary technology and is the only source capable to service the entire system.

1.5. Period of Performance: The period of performance shall start on the award of this contract and end with the completion of the second option period.

1.6. Local Requirements

1.6.1. Smoking Policy: The contractor shall comply with AR 600-63 that establishes policies governing smoking in Government facilities and ranges.

1.6.2. Government Inspections, Audits, and Surveys and Request for Information and Technical Advice:

1.6.2.1. In accordance with FAR 52.246-5, the contractor shall provide and maintain an inspection system acceptable to the Government covering the services under this contract. Complete records of all inspection work performed by the Contractor shall be maintained and made available to the Government during contract performance and for as long afterwards as the contract requires. The Government has the right to inspect and test all services called for by the contract, to the extent practicable at all places and times during the term of the contract. The Government shall perform inspections and tests in a manner that will not unduly delay the work. If any of the services performed do not conform to the contract requirements, the Government may require the contractor to perform the services again in conformity with contract requirements, for no additional fee. When the defects in services cannot be corrected by re-performance, the Government may (1) Require the contractor to take necessary action to ensure that future performance conforms to contract requirements; and (2) Reduce any fee payable under the contract to reflect the reduced value of the services performed. If the contractor fails to promptly perform the services again or take the action necessary to ensure future performance in conformity with contract requirements, the Government may (1) By contract or otherwise, perform the services and reduce any fee payable by an amount that is equitable under the circumstances; or (2) Terminate the contract for default. "Services", as used in this clause, includes services performed, workmanship, and material furnished or used in performing services.

1.6.2.2. The contractor shall respond to all requests for information and technical advice regarding the services in this contract. Responses shall be either verbal or written, as specified by the requester. Types of action shall include: Responding to inquiries and suggestions. Providing written comments based on review of draft documents such as regulations that affect the operations in this contract. Preparing reports in accordance with government instructions and directives by the requested due dates.

1.6.3. Work Hours: The normal work schedule for WDTC personnel is 0700 hours to 1730 hours Mountain Standard Time (MST), Monday through Thursday. The contractor shall be required to perform maintenance and service work during this work schedule. WDTC is located about 50 miles from the closes town which is Tooele Utah. Salt Lake City is located about 90 miles north of WDTC. WDTC is located on Dugway Proving Ground (DPG), Dugway Utah

1.6.4. AT/OPSEC: All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities and controlled access areas shall complete AT Level l awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee to the COR or to the contracting officer, if a COR is not assigned within 30 calendar days after completion of training by all employees and subcontractor personnel. AT Level l awareness training is available at the following website: https://atlevel1.dtic.mil/at.

1.6.5. Access and General Protection/Security Policy and Procedures: Contractor and all associated sub-contractors employees shall comply with applicable installation, facility, and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all persona identity verification requirements as directed by DOD, HQDA and/or local policy. In addition the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual or facility change, the Government may require changes in contractor security matters or processes.

1.6.6. iWATCH Training: The contractor and all associated sub-contractors shall brief all employees on the local iWATCH program (training standards provided by the requiring activity ATO). iWATCH training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the appropriate personnel. The government will provide iWATCH training package to contractor and associated sub-contractor for execution. iWATCH training shall be completed within 30 calendar days of contract award and prior to commencing work performance. Training results are to be reported to the COR prior to work performance.

Section 2. Definitions and Acronyms

Section 3. Government Furnished Property (GFP), Equipment, and Services:

Section 4. Contractor Furnished Items and Responsibilities

Section 5. Performance Requirements:

5.1 Preventative Maintenance CLIN 0001

5.1.1 The contractor shall perform the required preventative maintenance on the Multi-Shaker System components. The preventative maintenance shall be performed IAW the Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

Performance Standard

a) STD: The contractor shall perform all required preventative maintenance procedures IAW the manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

AQL: 100%

All work shall be performed by a qualified, experienced Spectral Dynamics Shaker System Technician and IAW the manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

5.1.2 The contractor shall provide only qualified experienced Spectral Dynamics Shaker System Technician to perform disassembly and assembly of the shaker system and to perform the required service test, inspections and services as required by the preventative maintenance program.

All work shall be performed by a qualified, experienced Spectral Dynamics Shaker System Technician and IAW the manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

5.1.3 The contractor shall perform the first preventative maintenance and service after the first 250 hours of operation or six (6) months whichever comes first. The second preventative maintenance and service at the 1000 hours of operation or before the end of the contract year.

Performance Standard

a) STD: The contractor shall perform all required preventative maintenance procedures IAW the COTS manual Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

AQL: 100%

The contractor shall perform all required maintenance and services on the multi-shaker system as recommended.

5.1.4 The contractor shall provide all parts and materials required to perform the required preventative maintenance. The parts include but not limited to all filters, current leads, hoses, clamps, oils, lubricants, fluids, pumps, wires, seals, and connectors.

Performance Standard

a) STD: The contractor shall provide all required parts and materials as required IAW the manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

AQL: 100%

The contractor shall provide all required parts including but not limited to all filters, current leads, hoses, clamps, oils, lubricants, fluids, pumps, wires, seals, and connectors as required IAW the manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

5.1.5 The contractor shall provide an inventory list of all service parts and materials used for each preventative maintenance and service performed. The inventory list shall include but not limited to model or part numbers, quantity, fluids, pumps, wires, seals, and connectors as required IAW the COTS manual Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

Performance Standard

a) STD: The contractor shall provide an inventory list of all service parts and materials used for each preventative maintenance and service IAW the COTS manual Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

AQL: 100%

Deliverable A0001 An inventory list including but not limited to model and/or part numbers, quantity, fluids, pumps, wires, seals, and connectors as required IAW the COTS manual Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

5.2 The components of the system includes the following subsystems:

5.2.1 Shaker System

a. Two (2) each SD-26400LS3-550 Electro dynamic shakers.

b. Two (2) each DPA184 power amplifiers.

c. Two (2) each WCU1 water cooling units

d. Two (2) each Model DA-16M Magnesium Drive Adapters with special features.

5.2.4 Multi-Shaker Control System:

a. One (1) Model 2580-9700-1 High Performance Acquisition/Control (ACP) system.

b. One (1) Model 2562-9458 Premier LINUX Desktop Controller.

5.3 Contract Management Reporting (CMR) (CLIN 0002)

5.3.1 The contractor shall inter all required information into the CMR system by the last day of October each year.

Performance Standard

a) STD: The contractor shall input all required manpower information into the CMR system by 31 October of each year IAW the CMR procedures and requirements.

AQL: 100%

The Contractor shall complete entry of the required CMR information.

Section 6. Deliverables

The contractor shall provide deliverables as described in this PWS. Deliverables are specified by the Government. Format and delivery schedule for deliverables are outlined in the PWS. It is incumbent upon the contractor to ensure that ALL deliverables, submittals, etc. whether they are summarized by the Government below or not, are submitted in accordance with this PWS. The following information is provided to assist the contractor in development and submittal of the required documents:

a. Description: The Inventory List shall be provided in grid format. The list shall include but is not limited to model and/or part numbers, quantity, fluids, pumps, wires, seals, and connectors as required IAW the COTS manual Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016. The list shall be type written or printed on standard size paper (8.5" x 11"), with the pages sequentially numbered and securely bound together. As necessary, graphic material may be one-way foldouts. All attachments shall be identified and referenced in the text. All documents shall be legible and reproducible and may also be requested in electronic format.

b. Delivery Instructions: The vendor shall provide an electronic copy to the COR and the KO (via email) of the Inventory List.

Section 7. Related References/Documents and Publications

The manual, Spectral Dynamics Preventative Maintenance Program for Multi-Shaker System, Dated 17 February 2016.

AR 750-43 ARMY Test, Measurement, and Diagnostic Equipment (TMDE) program.

Appendix A.

Preventative Maintenance Program for Multi-Shaker System

Preventative Maintenance Program for Multi-Shaker System

Table of Contents

7.0 Installation of the Upper Assembly…………………………………...…………………..8

1.0 Overview This preventative maintenance program for the multi-shaker system is to provide guidance for conducting preventative maintenance and services as required for the warranty on the shaker system.

2.0 Multi-Shaker system Components

2.1 SD-2600LS3-550 26,400 lbf Shaker System has the following components:

2.1.1 Electro dynamic shaker

2.1.2 DPA184 power amplifier

2.1.3 WCU1 water cooling unit

2.2 SD Model STGP-60-3 Platform Multi-Shaker Slip Table System

2.2.1 7 each linear guide bearings

2.2.2 Model IP-64x128 Rectangular Isolated Base

2.2.3 Model DA-16M Magnesium Drive Adapters (2) with special features

2.3 SD Multi-Shaker Vertical System

2.3.1 Model VGS-58D Vertical Guide/Load Bearing System

2.3.2 Model HE-S58D Octagonal Dual Magnesium Head Expander

2.3.3 Model HE-S58 Octagonal Head Expander

2.4 SD Multi-Shaker Control System

2.4.1 Model 2580-9700-1 High Performance Acquisition/Control (ACP) System

2.4.2 Model 2562-9458 Premier LINUX Desktop Controller

3.0 Preventative Maintenance for SD-26400 Shaker System Components

3.1 SD-26400-550 Electro Dynamic Shaker System(s)

3.1.1 Only a qualified experienced Shaker System Technician should perform disassembly and assembly of the shaker system. During the warranty period it is recommended that a complete preventative maintenance be performed after 250 hours of operation, and each 1000 hours of operation thereafter or every six (6) months whichever comes first.

3.1.2 To ensure maximum efficiency, a preventive inspection schedule should be followed. The operational schedule of the shaker determines the inspection schedule. A shaker operating daily should be inspected more frequently than a shaker that is used less frequently. Tightness of electrical connections and screws should be checked on regular basis prior to operating the system.

3.1.3 The following parts should be inspected while the shaker is disassembled:

3.1.3.1 Electrical Wiring

3.1.3.2 Terminal Block

3.1.3.3 Air Bag for Load Support

3.1.3.4 Field Coils

3.1.3.5 Armature Coils

3.1.3.6 Air Support System

3.1.3.7 Guidance System

3.1.4 Typical Wear Parts to be replaced during PM if required

3.1.4.1 Rubber Dustproof Ring

3.1.4.2 Nylon Flexure Board in Upper Guidance (12 pieces per shaker)

3.1.4.3 Guide Roller Kit in Upper Guidance (6 pieces per shaker)

3.1.4.4 Armature Current Lead Kit (2 pieces per shaker)

3.1.4.5 Lower Guide Shaft Assembly

3.1.4.6 Lower guide Self-lubricated slide bearing

3.1.4.7 Load Support Air Bag

3.2 DPA 184 Power Amplifier

3.2.1.1 Tests and Inspections (performed semi/annually):

3.2.1.2 Check the circuit breaker “trip test”

3.2.1.3 Clean the Transformer and power supply

3.2.1.4 High Current Joint Inspection

3.2.1.4.1 Cleanliness and tightness of all high-current joints is mandatory to prevent oxidation and overheating leading to major damage.

3.2.1.4.2 Inspect for signs of overheating or melted insulation on three-phase power lines, main circuit breaker, power transformer, power supply section

3.2.1.4.3 Do not remove any grease-like compound found on high current joints

3.3 WCU1 Water Cooling Unit

3.3.1.1 Tests and Inspections (performed semi/annually):

3.3.1.1.1 Check the hose connections

3.3.1.1.2 Check the water level and purity

3.3.1.1.3 Replace the water output filter core regularly

3.3.1.1.4 Dirty water will clog the filter causing the Water Flow Interlock to trigger.

3.4 Model STGP-60-3 Platform Slip Table Assembly Slip Plate and Bearings

3.4.1 The slip table assembly consists of a steel moat structure, a magnesium slip plate, a precision ground granite, a precision ground base plate, seven (7) guide bearings and a low pressure (100 psi) oil pump. The steel moat structure acts as an oil reservoir. The granite slip surface is enclosed within this structure and is ground and lapped to a tool room grade (Grade B) finish to provide minimum friction during vibration testing.

3.4.1.1 Extra care must be taken to protect the top surface of the slip plate from dents and heavy scratches. Dents on the top surface of the slip plate usually create bulges on the bottom of the slip plate, resulting in improper load distribution on the granite surface and a non-uniform oil film between the slip plate and the granite. This could result in damage to the slip table system or the shaker

3.4.1.2 The slip plate is internally ported from the aft end of the plate. The ports are 3/8” diameter and extend through the slip plate approximately 1” past the center of the slip plate. All future machining of the insert installation should have the outer diameter of the installed insert at least ½” from the centerline of the ports.

3.4.1.3 Attachment bolts used on the top surface of the slip plate should not be long enough to contact the bottom of the inserted holes. This could result in damage to the critical bottom surface.

3.4.1.4 Open cell foam sheets are installed around the perimeter of the granite for additional oil filtering. The foam filter is also used to wipe off the bottom of the slip plate during vibration to minimize dripping of the oil around the perimeter.

3.4.1.5 The guide bearings have a maximum stroke of 3.25”. They consist of 1.50” diameter aluminum sleeves riding on chrome plated steel shafts. The guide bearings do not require direct oil lubrication. However, they do receive some oil lubrication from internal splashing and misting of the system during vibration.

3.4.1.6 The oil pump removes oil from the bottom of the reservoir and directs it into the magnesium slip plate where it is expelled onto the top surface of the granite. The underside of the magnesium slip plate is routed to disperse the oil over the entire granite. The oil then flows over the edge of the granite and returns, through the foam filter, to the oil reservoir. The oil flow rate is set at the factory and should not be readjusted except by a qualified technician. The proper oil flow is critical to the operation of the slip table system. The oil pump operates off of standard 110v electrical power.

3.4.1.7 The correct oil to be use is Shell Tellus 68 or equivalent.

3.4.1.8 Turn on the oil pump and wait at least 15 minutes before stroking the slip plate, and 30 minutes before running a vibration test.

3.4.1.9 Do not over torque the bolts – see manual for proper torque settings.

3.4.1.10 For best results distribute test article load over as much of the slip plate surface as possible.

3.4.1.11 The six (6) vibration isolators which sit beneath the steel isolated platform were inflated to detailed pressures (in manual) at installation. These pressures should be periodically checked and maintained. The isolators can isolate to 3 ½ Hz with air pressure. Without air pressure they can isolate to 5 Hz.

3.4.1.12 Periodically check the oil level in the slip table moat using a dipstick. The oil level should be at least 1 ¾” deep. If below this level or if air bubbles are seen in the oil return lines, add Shell Tellus 68 (or equivalent) oil’

4.0 SD Vertical Testing Assembly: The vertical guidance and load support system (referred to as “the vertical system”) was designed and manufactured specifically to provide simple linear guidance and load re-centering capabilities. There are two separate vertical guided head expander systems. One system contains a 60” X 60” head expander for mounting to a single shaker. The other system contains a 60” X 60” head expander for mounting to dual shakers. Both systems consist of the following components:

4.1 One (1) each, 60.0” magnesium head expander weldment.

4.2 One (1) each, steel upper frame weldment.

4.3 One (1) each, steel lower frame weldment.

4.4 Six (6) each, steel lower leg weldments.

4.5 Eight (8) each, steel angled braces.

4.6 Eight (8) each, Steel flexure pedestals.

4.7 Two (2) each, steel lockout brackets with hardware.

4.8 Eight (8) each, laminated flexure assemblies.

4.8.1 Regular maintenance to inspect the torque values of the bolts and visual inspections to verify the integrity of the wrappings is important.

4.9 Four (4) each, Firestone airbags and related hardware.

4.9.1 Do not exceed 90 psig in the air bags. The air bags should be inflated very slowly when additional mass is added to the head expander system. Adjust the regulators until the head expander is at mid stroke. Record the regulator pressure with the system unloaded. This will become the system’s “set pressure.” Always return the air bags to the “set pressure” before removing any test articles from the system. This will prevent sudden inflation of the air bags and uncontrolled movement of the system.

4.9.2 Prior to removing any mass from the system, deflate the air bags to the “set pressure”. If the magnesium fixture table is being removed from the system, the air bags must be set to zero psig and the lockout pins must be installed.

4.10 Two (2) each, Aluminum lockout/stroke limit blocks.

4.10.1 This system is equipped with a stroke limitation device. In the event that the shaker travels beyond its normal operating stroke, the stroke limitation device provides a hard mechanical stop. This device should be set to allow full stroke of the shaker armature but prevent over extension of the shaker armature and flexure guidance. This device should be checked prior to each operation of the system.

4.11 Two (2) each, special stroke limitation studs and hardware.

4.12 One (1) each, Air regulator and gauge assembly.

4.13 Four (4) each, hoist rings.

4.14 Two (2) each, shaker amplifier cut-off interlock switches.

4.15 One (1) lot, miscellaneous hardware.

5.0 Vertical Operation: When loading the system to perform normal operation in the vertical axis, the assemblies should be located at their mid-stroke positions. All stroke-limiting devices should be at their mid-stroke positions. Once the load is attached to the system, and the lockout bolts are removed, the system is free to move vertically. When the test is complete, the head expander system should be at the mid-stroke position. Set the airbags to their set pressure, remove the mass from the system, and install the lockout pins.

6.0 Removal of the Upper Assembly: This system is designed to allow the upper portion of the head expander system to be removed while leaving the support legs in place. To remove the Frame Assembly along with the head expander, make certain that the head expander system is at the mid-stroke position.

6.1 Install the two (2) lockout pins into the lockout receivers on the head expander. This is done by inserting the pins through the steel lockout brackets.

6.2 Remove the armature bolts from the head expander.

6.3 Relieve pressure from all airbags and disconnect the quick-disconnect fittings on the air-lines.

6.4 Support the system with an overhead hoist at the lifting ring locations.

6.5 Remove the bolts, nuts and washers that attach the Upper frame assembly to the Lower frame assembly.

6.6 Lift the Frame Assembly and set in a safe place. The Lower frame assembly and support legs should remain mounted to the floor/mass.

7.0 Installing The Upper Assembly

7.1 Verify shaker(s) are in the vertical position. Install 2 each, 24” long M10 threaded rods into the armature inserts (use the 500mm diameter bolt circle at 180 degrees apart). For installing the dual shaker assembly, install the 2 threaded rods on center of each armature.

7.2 Lower the Upper frame assembly onto the shaker armature(s), using the threaded rods for guidance. The Upper frame assembly should not depress the armature during this step. Check all outer armature insert locations to be certain they are all contacting the bottom of the Head Expander. Keep the overhead hoist attached at all times during the assembly process for added support and safety.

7.3 Install and tighten all of the 3/8-24 bolts, nuts and washers between the Upper frame assembly and the Lower frame assembly.

7.4 Attach the shop air supply to the air regulators/manifold.

7.5 Apply enough pressure to the head expander support airbags to release the lockout pins. Remove the lockout pins and lower the airbag pressure until the head expander comes into contact with the armature face.

7.6 Visually inspect system as this process is taking place to insure safety for personnel and vibration equipment.

7.7 Install two (2) M10 socket head cap screws (Customer supplied) into the shaker armature’s outer bolt circle at 180 apart. Torque to Spectral Dynamic’s specified value.

7.8 Remove both of the M10 threaded rods from the shaker armature.

7.9 Install the remaining M10 socket head cap screws into the shaker armature.

7.10 Torque all attachment bolts to their specified torque value.

7.11 Gradually lower the hoist.

7.12 Remove the hoist rings from the system. (Optional)

7.13 Inflate the air bags as necessary to position the shaker armature to mid-stroke.

7.14 Check the stroke of the shaker armature to verify the mid-stroke position of the stroke limitation blocks.

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